Case Study

� e SituationThe new FedEx® Ground Distribution Hub in

Middletown, Connecticut, would be one of the

largest construction projects in the state of

Connecticut. The scope of the project included

over 300,000 square feet of segmental retaining

wall block built to maximum heights of 60 feet—

making it one of the largest and tallest SRW

projects in North America.

Due to the size, complex installation

and overall scope of the wall project,

we knew right from the start it would

have to be a collaborative eff ort by all

to be a success story.

Chip George

General Manager for Earth Retention Systems, LLC

“The general contractor Manafort Brothers,

Earth Retention Systems, Advantage Engineers

and the Belgard Commercial team all worked

together to make that happen.”

The project broke ground in May 2016 and

according to representatives at FedEx is part

of a nationwide expansion resulting from the

exponential increase in the number of daily

packages shipped over the last 10 years. The

260-acre site would house a 525,000-square

foot main hub building, along with a

maintenance garage and salt storage shed.

� e SolutionThe project involved an astounding 2.5 million

cubic yards of earthwork that required six

retaining wall structures, encompassing

over 11,000 linear feet of SRW’s to re-grade,

stabilize and optimize the site. The project

also called for over 650,000 square yards of

Mirafi ® geosynthetic reinforcement. Oldcastle

worked with the project’s retaining wall

design engineers during the design phase

to secure the Vertica® Retaining Wall System

with Mirafi ® geosynthetic reinforcement as

the basis of the SRW design for the project.

“The design of the massive walls needed a

proven system such as Vertica Wall with Mirafi

geogrid reinforcement,” said Scott Vollmer,

SRW Market Manager for Oldcastle APG’s

East region. “Vertica's four-degree batter was

another advantage of the system and allowed

for optimal site layout.”

Due to the size, complex installation

have to be a collaborative eff ort by all

FEDEX GROUND DISTRIBUTION HUBVertica Wall Solution Rises to the Challenge

LOCATION:

Middleton, Connecticut

MANUFACTURED BY:

Anchor, an Oldcastle® Company

PRODUCT:

Vertica® Retaining Wall SystemMirafi Geosynthetic Reinforcement

CONTRACTOR:

Earth Retention Systems, LLC

WALL DESIGNER:

Advantage Engineers, LLC

CIVIL ENGINEER/ARCHITECT:

BL Companies

GENERAL CONTRACTOR:

Manafort Brothers Incorporated

Case Study

Vertica Wall was shown to be a viable

produt that could hold up to the

structural needs of the project, look

good for the client, and hit all of the

other marks in terms of competitive

price and a demanding square-foot-

per-day delivery timeline.

Joshua Krebs

Advantage Engineers/Project Designer

� e ResultsAnchor, an Oldcastle® Company, was selected

as the exclusive supplier of the retaining wall

and geogrid materials using Anchor's Cranston,

Rhode Island, plant to manufacture the SRW

units. “This selection was based on competitive

price, proximity to the project, technical support,

manufacturing capabilities, and the overall

resources to supply such a large project on a

tight time frame,” Vollmer said.

“We worked closely with BL Companies (site civil

engineer) to help optimize the retaining walls

in context with the overall site design. Anchor

was helpful in providing technical resources

and were very responsive to everyone’s needs

throughout the process,” Krebs added. “From a

delivery standpoint, the materials were provided

on the scheduled timeline that was needed.”

As of July 1, 2018, the entire segmental retaining

wall project was completed to the customer’s

satisfaction accomplishing one of the biggest

and most complex SRW applications in North

America. “I’m very proud of all the companies

and individuals who helped make this one of

the most successful SRW projects within the

Oldcastle family,” said Greg Piper, VP of Sales

for Anchor, North Region.

Vertica Wall was shown to be a viable

price and a demanding square-foot-

© Copyright 2018 Oldcastle. BELCOMM18-976 11/18. All Rights Reserved.

FEDEX GROUND DISTRIBUTION HUB

About Belgard® Belgard is part of Oldcastle APG, Inc, the largest concrete products manufacturer in North America. With over 180 locations and a company culture characterized by a commitment to customer satisfaction, Oldcastle adheres to a level of service and consistency that no other supplier can match. Our combination of local market presence and national capabilities allows us to meet and exceed the demanding needs of an ever-changing industry.

About Vertica® Wall• Designed for steep, sloping hillsides and other structural challenges.

• Can be built to virtually any height in incredibly tight spaces.

• Design allows for reduction of excavation, land loss and labor hours.

• Features warm earth-tone colors and rugged, rock-like face.

• Can build taller walls with geosynthetic reinforcement

or the Anchorplex™ system when designed by a qualifi ed engineer.